Slew-actuated piercing of radial wall

ABSTRACT

A slew-actuated stamping station includes an expandable core configured to apply radially outward pressure to a radially inward facing surface of a radial wall, and at least one slew-actuated punch for piercing, along a radially inward direction, a respective hole in the radial wall. A method for piercing a radial wall includes simultaneously (a) applying radially outward pressure against a radially inward facing surface of the radial wall, and (b) driving a slew to actuate at least one punch to pierce, along direction opposite the radially outward pressure, at least one hole in the radial wall. A method for forming an object, having a radial wall with holes, includes forming a ring with a radial wall, and piercing at least one hole in the radial wall with at least one slew-actuated punch.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/029,401, filed Jul. 6, 2018 (now U.S. Pat. No. 10,888,912), whichclaims the benefit of priority of U.S. Provisional Patent ApplicationNo. 62/530,080, filed Jul. 7, 2017. Each of these applications isincorporated herein by reference in its entirety.

BACKGROUND

Sheet metal rings with holes in the side wall are typically produced bypunching the holes in the sheet metal and, subsequently, bending thesheet metal to form the ring. In such systems, the sheet metal may bepassed through a hole punch machine that uses a single punch to puncheach individual hole sequentially.

SUMMARY

In an embodiment, a slew-actuated stamping station includes anexpandable core configured to apply radially outward pressure to aradially inward facing surface of a radial wall, and at least oneslew-actuated punch for piercing, along a radially inward direction, arespective hole in the radial wall.

In an embodiment, a method for piercing a radial wall includessimultaneously (a) applying radially outward pressure against a radiallyinward facing surface of the radial wall, and (b) driving a slew toactuate at least one punch to pierce, along direction opposite theradially outward pressure, at least one hole in the radial wall.

In an embodiment, a method for forming an object, having a radial wallwith holes, includes forming a ring with a radial wall, and piercing atleast one hole in the radial wall with at least one slew-actuated punch.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a slew-actuated stamping station, according to anembodiment.

FIGS. 2A and 2B illustrate an expandable core that includes a pluralityof die segments, according to an embodiment.

FIGS. 3A and 3B illustrate one embodiment of the slew-actuated stampingstation of FIG. 1.

FIG. 4 illustrates two instances of a slew-actuated stamping stationimplemented in a stamping system, according to an embodiment.

FIG. 5 is a top view of the stamping station of FIG. 4.

FIGS. 6 and 7 show the stamping station of FIGS. 4 and 5 in furtherdetail.

FIG. 8 illustrates a punch assembly having a single punch, according toan embodiment.

FIG. 9 illustrates a punch assembly having two punches, according to anembodiment.

FIG. 10 illustrates an expandable core including a plurality of diesegments, according to an embodiment.

FIGS. 11 and 12 illustrate a stamping station 1100 with a gripper,according to an embodiment.

FIGS. 13A and 13B illustrate a cylindrical ring that has been pierced instamping station, according to an embodiment.

FIGS. 14A and 14B illustrate a pierced ring with a circumference thatvaries along the axial dimension, according to an embodiment.

FIG. 15 illustrates an expandable core having rounded die segments,according to an embodiment.

FIGS. 16A and 16B illustrate another pierced ring with a circumferencethat varies in the axial dimension, according to an embodiment.

FIG. 17 illustrates an expandable core having conical die segments,according to an embodiment.

FIG. 18 illustrates a ring having a cylindrical wall and a lip extendingfrom the cylindrical wall, according to an embodiment.

FIG. 19 illustrates certain alternative configurations of holes piercedin a radial wall by stamping station, according to embodiments.

FIG. 20 illustrates another stamping system, according to an embodiment.

FIG. 21 is a flowchart of a method for slew-actuated piercing a radialwall, according to an embodiment.

FIG. 22 is a flowchart of a method for performing a plurality ofslew-actuated piercing operations on an object having a radial wall,according to an embodiment.

FIG. 23 is a flowchart of a method for forming an object having a radialwall with holes, according to an embodiment.

FIG. 24 illustrates a speed ring, according to an embodiment.

FIG. 25 illustrates a bearing cage, according to an embodiment.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 illustrates one slew-actuated stamping station 100. Stampingstation 100 is configured to pierce one or more holes in a ring-shapedpart having a radial wall. Stamping station 100 may form several holesin the radial wall in a single punching operation. Stamping station 100includes an expandable core 120 that holds a part 190 having a radialwall 192. When expanded, core 120 applies radially outward pressure 122to a radially inward facing surface 196 of radial wall 192.

Herein, “radially inward” refers to a direction that is substantiallytoward an axis 198 of part 190, and “radially outward” refers to adirection that is substantially away from axis 198. In one example, part190 has cylinder symmetry and axis 198 is the cylinder axis. In anotherexample, the intended use of part 190 (when finished) involves rotationabout a rotation axis inside radial wall 192, and axis 198 is therotation axis. The radially inward and radially outward directions maydeviate from being exactly perpendicular to axis 198, without departingfrom the scope hereof. For example, for a cylindrical embodiment ofradial wall 192, the radially inward and radially outward directions maydeviate somewhat from perpendicular incidence on radial wall 192, suchas by up to 10 or 45 degrees.

Stamping station 100 further includes at least one slew actuated punch110 that moves along a radially inward direction 150. Each punch 110thereby pierces a respective hole 194 in radial wall 192. Each punch 110moves to perform the piercing operation in a single slew-actuated move.Embodiments of stamping station 100 equipped with a plurality of punches110 are capable of simultaneously forming a plurality of holes 194 inradial wall 192, wherein the plurality of holes 194 may be located atdifferent azimuthal positions (relative to axis 198).

Expandable core 120 enables a tight fit of inward facing surface 196 ofpart 190 onto core 120. In exemplary operation, part 190 is placed instamping station around expandable core 120 with expandable core beingsized smaller than inward facing surface 196. Subsequently, expandablecore 120 is expanded to form a tight fit with inward facing surface 196.This tight fit secures part 190 in stamping station 100. In addition,expandable core 120 may, by virtue of radially outward pressure 122,shape and/or size radial wall 192 to achieve a desired final shapeand/or size. For example, the expandable core 120 may ensure thatradially inward facing surface 196 has circular cross section at everyaxial position of radial wall 192. Without departing from the scopehereof, the shape and/or size of part 190 may be modified in lateroperations. In one example, the radially outward pressure applied byexpandable core 120 improves the roundness of radial wall 192. Inanother example, expandable core 120 slightly expands radial wall 192 toachieve a final size. For non-cylindrical parts 190, for example aconical radial wall 192 or a radial wall 192 having several cylindricalsections with different diameters, the radially outward facing surfaceof core 120 applying the radially outward pressure may be shaped tomatch the shape of at least a portion of radially inward facing surface196 (or a desired final shape/size thereof). Furthermore, the radiallyoutward pressure applied by core 120 during piercing of radial wall 192may serve to prevent distortion of radial wall 192 during the piercingoperation. The radially outward pressure applied by core 120 duringpiercing of radial wall 192 may also serve to prevent formation of burrsat holes 194 during the piercing operation.

In one embodiment, stamping station 100 includes a drive ring 130 and atleast one slew 112 that drives rotation of drive ring 130 along asubstantially azimuthal direction 140 (relative to axis 198) to moveeach punch 110 along a respective radially inward direction 150. Eachslew 112 may be coupled with a drive, such as a servo drive, that drivesthe rotation of slew 112.

FIGS. 2A and 2B illustrate one expandable core 200 that includes aplurality of die segments 210. Die segments 210 are arranged about atapered plunger 220. FIGS. 2A and 2B shows expandable core 200 andtapered plunger 220 in perspective view and cross-sectional side view,respectively. FIGS. 2A and 2B are best viewed together in the followingdescription.

Expandable core 200 is an embodiment of expandable core 120 and may beimplemented in stamping station 100 together with tapered plunger 220.In operation, when implemented in stamping system 100, tapered plunger220 is lowered to push die segments 210 radially outward from an axis298 along respective directions 222 to apply radially outward pressure122. When implemented in stamping station 100 to hold part 190, axis 298may coincide with axis 198.

In an embodiment, one or more of die segments 210 form a receptacle orchute 212 configured to accept respective punch 110, after punch 110 haspierced through radial wall 192, and/or to accept material pierced outof radial wall 192 by punch 110. Such material may pass throughreceptacle/chute 212 as indicated by arrow 214.

FIGS. 3A and 3B illustrate a slew-actuated stamping station 300 that isan embodiment of stamping station 100. FIG. 3A shows an initialconfiguration of stamping station 300 after having received part 190.FIG. 3B shows a configuration of stamping station 300 after piercing ofradial wall 192 of part 190. FIGS. 3A and 3B are best viewed together.

Stamping station 300 includes a drive ring 330, at least one punch 310,and a guide 360. Stamping station 300 also includes expandable core 120,which may be implemented as expandable core 200 together with taperedplunger 220. Each punch 310 is mounted on a punch body 340 that isconnected to drive ring 330 via a lever 350. Without departing from thescope hereof, each punch body 340 may have more than one punch 310mounted thereto. Guide 360 restricts the motion of each punch body 340,and hence each punch 310, to be radially inward or radially outward.Although for clarity not depicted in FIGS. 3A and 3B, stamping station300 may further include one or more slews 112 to actuate drive ring 330.

The joint between lever 350 and punch body 340 allows for pivoting oflever 350 about a pivot axis 352. The joint between lever 350 and drivering 230 allows for pivoting of lever 350 about a pivot axis 354. Eachof pivot axes 352 and 354 may be parallel to axis 198 (when part 190 ismounted in stamping station 300).

As shown in FIG. 3A, part 190 is mounted on expandable core 120 while(a) drive ring 330 is positioned such that each pivot axis 354 is at adifferent azimuthal position than the corresponding pivot axis 352 and(b) expandable core 120 is sized smaller than radial wall 192. Thisensures that punch(es) 310 are retracted away from radial wall 192.Next, as shown in FIG. 3B, expandable core 120 is expanded andslew-actuation rotates drive ring 330 along direction 140. Upon thisrotation, each pivot axis 354 is moved to an azimuthal position that iscloser to the azimuthal position of the corresponding pivot axis 352.This results in movement of the corresponding punch body 340 radiallyinward, in guide 360 along radially inward direction 150, to pierceradial wall 192 with one or more punches 310 mounted on punch body 340.In the example shown in FIGS. 3A and 3B, each punch 310 is at itsradially most inward position when lever 350 is parallel to punch body340. In an embodiment, the azimuthal displacement of drive ring 330between FIGS. 3A and 3B is in the range between 5 and 20 degrees. Whenpiercing is complete, drive ring 330 may rotate back to the positionshown in FIG. 3B. Alternatively, drive ring 330 may rotate in the sameazimuthal direction 140 as from FIG. 3A to FIG. 3B until each punch 310is retracted from radial wall 192.

FIG. 4 illustrates two instances 400(1) and 400(2) of one slew-actuatedstamping station 400 implemented in an exemplary stamping system 402.FIG. 5 is a top view of stamping station 400. Stamping station 400 is anembodiment of stamping station 100. FIGS. 4 and 5 are best viewedtogether in the following description.

Each stamping station 400 includes an expandable core 520 which is anembodiment of expandable core 200. Each stamping station 400 furtherincludes a tapered plunger 525 which is an embodiment of tapered plunger220. Each stamping station 400 also includes at least one slew 410 thatactuates one or more punches 510 to move along a radially inwarddirection 550. In addition, each stamping station 400 includes a drivering 530. Slew(s) 410 drive rotation of drive ring 530 along asubstantially azimuthal direction 540 (relative to axis 198) to moveeach punch 510 along a respective radially inward direction 550. Eachslew 410 may be coupled with a drive 412, such as a servo drive, thatdrives the rotation of slew 410. Stamping station 400 is an embodimentof stamping station 300. While the embodiment of stamping station 400illustrated in FIGS. 4 and 5 includes two slews 410 and a plurality ofpunches 510, stamping station 400 may be configured with only a singleslew 410, more than two slews 410, and/or only a single punch 510.

Stamping system 402 may include one or more grippers 460 that grip part190 to move part 190 to different positions in stamping system 402. Inone example, a first gripper 460 is configured to place part 190 instamping station 400(1), a second gripper 460 is configured to move part190 from stamping station 400(1) to stamping station 400(2), and a thirdgripper 460 is configured to extract part 190 from stamping station400(2).

Without departing from the scope hereof, stamping system 402 may includeadditional instances of stamping station 400. Stamping system 402 mayreplace each of one or more stamping stations 400 with anotherembodiment of stamping station 100.

FIGS. 6 and 7 illustrate stamping station 400 in further detail. FIG. 6shows a sectional view of stamping station 400, wherein the section cutcoincides with the location of axis 198 when part 190 is mounted instamping station 400. For clarity of illustration, FIG. 6 shows stampingstation 400 without part 190 mounted therein. FIG. 7 shows a top view ofstamping station 400 (not including slew(s) 410).

Expandable core 520 has a plurality of die segments 610. Die segments610 and tapered plunger 525 meet at a tapered interface 612, such thatlowering of tapered plunger 525 pushes die segments 610 radiallyoutward, thereby expanding core 520.

Each punch 510 of stamping station 400 is mounted on a punch body 640.Each punch body 640 is connected to drive ring 530 via a lever 650. Thejoint between lever 650 and punch body 640 allows for pivoting of lever650 about a pivot axis 652. The joint between lever 650 and drive ring530 allows for pivoting of lever 650 about a pivot axis 654. Each ofpivot axes 652 and 654 may be parallel to axis 198 (when part 190 ismounted in stamping station 400). Stamping station 400 further includesa guide 660 (an embodiment of guide 360) that restricts movement of eachpunch body 640 to a radially inward direction 550.

In an embodiment, each punch 510 is associated with a chute 670 in acorresponding one of die segments 610. Chute 670 receives materialpunched out of radial wall 192 by punch 510 and drops this material.

FIG. 8 illustrates one punch assembly 800 having a single punch 510.Punch assembly 800 may be implemented in stamping station 400. Punchassembly 800 includes punch body 640 and lever 650, configured asdiscussed above in reference to FIGS. 6 and 7. Punch assembly furtherincludes a mount 860 configured to couple the distal end of lever 650 todrive ring 530. Punch body 640 has a single punch 510 mounted on theproximate end of punch body 640. Herein, “distal” and “proximate” referto positions or parts that are further away from and closer to,respectively, axis 198 of part 190 when part 190 is mounted in thestamping station.

FIG. 9 illustrates one punch assembly 900 having two punches 510. Punchassembly 900 is similar to punch assembly 800 except for having twopunches 510 mounted on the proximate end of punch body 640. Withoutdeparting from the scope hereof, punch assembly 900 may have more thantwo punches 510 mounted on the proximate end of punch body 640.

FIG. 10 illustrates an expandable core 1000 including a plurality of diesegments 1010. Expandable core 1000 is an embodiment of expandable core520, and die segment 1010 is an embodiment of die segment 610. Each diesegment 1010, coinciding with a location for piercing by a punch 510,forms a receptacle 1070 for punch 510. Receptacle 1070 may continuethrough the die segment 1010 to form an example of chute 670.

FIGS. 11 and 12 illustrate one exemplary stamping station 1100 thatcombines stamping station 400 with a gripper 460. FIG. 11 shows asectional side view of stamping station 400. FIG. 12 shows a close-up ofa portion 1190 of stamping station 1100. FIGS. 11 and 12 are best viewedtogether in the following description. In the embodiment shown in FIG.12, stamping station 1100 includes a drive 1240 that controls the motionof tapered plunger 525 to expand or shrink expandable core 520.

Without departing from the scope hereof, stamping station 1100 may havemore than one gripper 460. In one example, a first gripper 460 isconfigured to place part 190 in stamping station 400 and a secondgripper 460 is configured to extract part 190 from stamping station 400.

FIGS. 13A and 13B illustrate one cylindrical ring 1300 that has beenpierced in stamping station 100. FIG. 13A shows cylindrical ring 1300 inperspective view. FIG. 13B shows a cross sectional view of cylindricalring 1300 with the cross section taken in a radial plan. FIGS. 13A and13B are best viewed together in the following description. Cylindricalring 1300 is a cylindrical wall 1310 with a plurality of holes 1320formed therein by stamping station 100. The cylinder axis of cylindricalring 1300 coincides with axis 198. In an embodiment, holes 1320 areequidistantly spaced in the azimuthal direction (relative to axis 198).Although FIG. 13A shows holes 1320 as being rectangular, holes 1320 mayhave a different shape without departing from the scope hereof. Forexample, holes 1320 may be circular, polygonal with three or more sides,or a more complex shape.

FIGS. 14A and 14B illustrate one pierced ring 1400 with a circumferencethat varies along the axial dimension. Ring 1400 has been pierced instamping station 100. FIG. 14A shows ring 1400 in perspective view. FIG.14B shows a cross sectional view of ring 1400 with the cross sectiontaken in a radial plan. FIGS. 14A and 14B are best viewed together inthe following description. Ring 1400 has a radial wall 1410 with aplurality of holes 1420 formed therein by stamping station 100. Anycross section of radial wall 1410, taken in a plane orthogonal to axis198, is substantially circular (apart from missing portions at holes1420). However, the diameter of the cross section varies along axis 198.In an embodiment, holes 1420 are equidistantly spaced in the azimuthaldirection (relative to axis 198). Although FIG. 14A shows holes 1420 asbeing rectangular, holes 1420 may have a different shape withoutdeparting from the scope hereof as discussed above in reference to FIG.13A. Also without departing from the scope hereof, the variation of thediameter along axis 198 may be different from that shown in FIGS. 14Aand 14B.

FIG. 15 illustrates one expandable core 1500 having rounded die segments1510. Expandable core 1500 is an embodiment of expandable core 200 thatis configured to hold ring 1400 during piercing in stamping station 100.Each die segment 1510 has a rounded radially-outward-facing surface 1512that matches the shape of ring radial wall 1410, such that, when taperedplunger 220 forces die segments 1510 radially outward, a tight fit isachieved between die segments 1510 and radial wall 1410. One or more diesegments 1510 may form receptacle/chute 212. It is understood thatradially-outward-facing surfaces 1512 may modify the shape of radialwall 1410 when expandable core 1500 is expanded against radial wall1410, so as to achieve a final desired shape of radial wall 1410.

FIGS. 16A and 16B illustrate another pierced ring 1600 with acircumference that varies in the axial dimension. Ring 1600 has beenpierced in stamping station 100. FIG. 16A shows ring 1600 in perspectiveview. Ring 1600 is formed from a single piece. FIG. 16B shows a crosssectional view of ring 1600 with the cross section taken in a radialplan. FIGS. 16A and 16B are best viewed together in the followingdescription. Ring 1600 has a conical radial wall 1610 and a lip 1612extending from conical radial wall inwards toward axis 198. Conicalradial wall 1610 has a plurality of holes 1620 formed therein bystamping station 100. Any cross section of conical radial wall 1610,taken in a plan orthogonal to axis 198, is substantially circular (apartfrom missing portions at holes 1620). However, the diameter of the crosssection varies along axis 198. In an embodiment, holes 1620 areequidistantly spaced in the azimuthal direction (relative to axis 198).Although FIG. 16A shows holes 1620 as being rectangular, holes 1620 mayhave a different shape without departing from the scope hereof asdiscussed above in reference to FIG. 13A. Also without departing fromthe scope hereof, the variation of the diameter along axis 198 may bedifferent from that shown in FIGS. 16A and 16B. For example, thediameter of conical radial wall 1610 may decrease in the direction awayfrom lip 1612, or conical radial wall 1610 may be at least partlyreplaced by a rounded wall similar to radial wall 1410 of ring 1400. Inthe embodiment shown in FIGS. 16A and 16B, lip 1612 is orthogonal toaxis 198. Alternatively, lip 1612 may be at an oblique angle to axis198.

FIG. 17 illustrates one expandable core 1700 having conical die segments1710. Expandable core 1700 is an embodiment of expandable core 200 thatis configured to hold ring 1600 during piercing in stamping station 100.Each die segment 1710 has an angled radially-outward-facing surface 1712that matches the shape of ring radial wall 1610, such that, when taperedplunger 220 forces die segments 1710 radially outward, a tight fit isachieved between die segments 1710 and radial wall 1610. One or more diesegments 1710 may form receptacle/chute 212. It is understood thatradially-outward-facing surfaces 1712 may modify the shape of radialwall 1610 when expandable core 1700 is expanded against radial wall1610, so as to achieve a final desired shape of radial wall 1610.

FIG. 18 illustrates one ring 1800 having a cylindrical wall 1810 and alip 1820 extending from cylindrical wall 1810. Ring 1800 is formed froma single piece. Lip 1820 is orthogonal to axis 198. Ring 1800 may beplaced in stamping station 100 for piercing of holes in cylindrical wall1810.

For each of the embodiments discussed above in reference to FIGS.13A-18, stamping station 100 may be configured with an expandable corehaving a radially outward facing surface that matches at least a portionof the inward facing surface of the radial wall to be pierced (e.g.,wall 1310, 1410, 1610, or 1810).

FIG. 19 illustrates certain alternative configurations of holes piercedin a radial wall by stamping station 100. A ring 1910 has a radial wall1912 with a plurality of holes 1914 that are not equidistantly spaced inthe azimuthal dimension 1916. Another ring 1920 has a radial wall 1922with holes 1924 pierced in locations that are not centered on radialwall 1922 in the axial dimension. Yet another ring 1930 has a radialwall 1932 with a plurality of holes 1934 that are not identical inshape. It is understood that each of the radial walls discussed inreference to FIGS. 1-18 may have holes according to one or more of theconfigurations shown in FIG. 19.

FIG. 20 illustrates one exemplary stamping system 2000 in top view (topof FIG. 20) and side view (bottom of FIG. 20). Stamping system 2000includes two instances 400(1) and 400(2) of stamping station 400. Thetwo stamping stations 400(1) and 400(2) may pierce different holepatterns. Stamping system 2000 receives a part at location 2010. Whenconfigured for handling rings with a weld (such as when forming the ringby roll-forming a flat sheet), a gripper moves the part to a rotarystation 2020 that orients the weld according to a predefinedorientation. For rings that do not have a weld, or if the weldorientation is not significant, stamping system 2000 may omit rotarystation 2020. Next, a gripper moves that part to a first stampingstation 400(1) for stamping of one or more first holes. Subsequently, agripper moves the part to a second stamping station 400(2) for stampingof one or more second holes. The second hole(s) may be formed in thesame radial wall as the first holes. Alternatively, if the part includesmore than one radial wall or radial wall segments, the first and secondhole(s) may be formed in respective first and second radial walls orwall segments. Stamping system 2000 may be configured to maintain a weldorientation through each station of stamping system 2000.

Since stamping system 2000 has two stamping stations 400, stampingsystem 2000 may be capable of piercing more holes than a single stampingstation 400, for example if piercing of all holes by a single stamping400 would result in distortion of the ring or require more power thancan be supplied by a single stamping station 400.

System 2000 may be configured to transfer the pierced ring to anothermachine that further modifies the shape of the ring. For example, agripper may transfer the ring to a roll-forming apparatus to change theshape of the radial wall.

FIG. 21 is a flowchart of one exemplary method 2100 for slew-actuatedpiercing a radial wall. Method 2100 may be performed by stamping station100 as discussed in the foregoing. In a step 2110, method 2100 applies aradially outward pressure against a radially inward facing surface ofthe radial wall. In one example of step 2110, expandable core 120applies radially outward pressure 122 against radially inward facingsurface 196 of radial wall 192. Step 2110 may include one or more ofsteps 2112, 2114, 2116, and 2118. Optional step 2112 expands a core,e.g., expandable core 120, to apply the radially outward pressure, e.g.,radially outward pressure 122. Optional step 2114 achieves final sizeand/or shape of the radially inward facing surface by virtue of theapplied radially outward pressure. Optional step 2116 prevents burrs inthe radial wall by virtue of the applied radially outward pressure.Optional step 2118 prevents distortion of the radial wall by virtue ofthe applied radially outward pressure.

In a step 2120, method 2100 drives at least one slew to actuate at leastone punch to pierce, along a direction substantially opposite theradially outward pressure, at least one hole in the radial wall. Step2120 may include one or both of steps 2122 and 2124. Step 2122 drivesthe slew(s) to rotate a drive ring, coupled to the slew(s) and eachpunch, to move each punch. In one example of step 2122, slew 112 rotatesdrive ring 130 to move punch(es) 110 radially inward along direction150. Step 2124 guides movement of each punch along a radially-inwarddirection to pierce the radial wall. In one example of step 2124, guide360 guides the movement of one or more punch bodies 340. Step 2122 and2124 may be performed simultaneously.

Method 2100 may maintain the radially outward pressure of step 2110while performing step 2120.

FIG. 22 is a flowchart of one exemplary method 2200 for performing aplurality of slew-actuated piercing operations on an object having aradial wall. Method 2200 is for example performed by stamping system2000 as discussed above in reference to FIG. 20.

In a step 2210, the stamping system receives an object with a radialwall. In one example of step 2210, stamping system 2000 receives part190. In a step 2230, method 2200 performs method 2100 in a firststamping station to pierce one of more first holes in the radial wall.In one example of step 2230, stamping station 400(1) of stamping system2000 pierces one or more holes 194 in radial wall 192. In a step 2240,method 2200 performs method 2100 in a second stamping station to pierceone of more second holes in the radial wall. In one example of step2240, stamping station 400(2) of stamping system 2000 pierces one ormore additional holes 194 in radial wall 192. In a step 2250, method2200 outputs the object with the pierced radial wall.

In one embodiment of method 2200, the object is a welded ring. Thiswelded ring may have a weld seam used to complete roll-forming of a ringfrom a flat sheet. In this embodiment, (a) step 2210 implements a step2212 of receiving a welded ring, (b) method 2200 further includes a step2220 of orienting the weld seam, for example such that the weld seam isaway from locations to be pierced in a subsequent step of method 2200,(c) step 2230 implements a step 2232 of maintaining the weld seamorientation, and (d) step 2240 implements a step 2242 of maintaining theweld seam orientation. In one example of this embodiment of method 2200,stamping system 2000 receives part 190, wherein radial wall 192 has aweld seam that is parallel to axis 198, and one or more grippers (suchas gripper 460) orients part 190 and maintains its orientation such thatthe weld seam is away from any location to be pierced by a stampingstation 400.

Without departing from the scope hereof, method 2200 may omit step 2240.

FIG. 23 is a flowchart of one exemplary method 2300 for forming anobject having a radial wall with holes. In certain embodiments, method2300 combines advantages of roll-forming (e.g., material savings) withthe efficient slew-actuated piercing process of method 2100.

In a step 2310, method 2300 forms a ring with a radial wall. In oneembodiment, step 2310 includes a step 2312 of roll-forming the ring froma flat sheet. This roll-forming process may produce a ring that has aweld seam. Step 2312 may include a step 2314 of forming a plurality ofsections along the axial dimension of the ring, wherein at least two ofthe sections have mutually different polar angles relative to axis ofthe ring. Herein, “polar angle relative to the axis” refers to the angleof the ring relative to the axis in a planar cross section that includesthe axis (e.g., axis 198), equivalent to the polar angle of a sphericalcoordinate system. FIGS. 14A, 14B, 16A, and 16B show examples of ringswith sections that have different polar angles relative to axis 198. Inanother embodiment, step 2310 includes a step 2316 of cutting the ringfrom a tube. Step 2316 may include a step 2318 of roll-forming the cutring to have a plurality of sections along the axial dimension of thering, wherein at least two of the sections have mutually different polarangles relative to axis of the ring.

In a step 2320, method 2300 performs method 2100 or method 2200 topierce one or more holes in at least one radial wall of the ring.

Method 2300 may further include a step 2330 of modifying the shape ofthe pierced ring. Step 2330 may include a step 2332 of roll-forming thepierced ring. In one example of step 2330, the shape of ring 190 ismodified after piercing by stamping system 2000 or stamping station 400.

FIG. 24 illustrates one exemplary speed ring 2400 that has been piercedby stamping station 100 according to method 2100. Speed ring 2400 has acylindrical wall 2410 with a plurality of holes 2420 formed by stampingstation 100. Speed ring 2400 is similar to cylindrical ring 1300. In anembodiment, speed ring 2400 is roll-formed from a flat sheet and weldedat the seam, prior to piercing of holes 2420 by stamping station 100. Inthis embodiment, stamping station 100 may maintain the orientation ofthe weld seam to ensure that no punches 110 go through the weld seam. Anexemplary weld seam 2450 is indicated in FIG. 24. Alternatively, weldseam 2450 could be orientated such that punches 110 do go through weldseam 2450.

Speed ring may be made of steel, such as AISI low carbon steel, and have(a) diameter 2472 in the range between 5 and 10 inches and (b) radialwall thickness 2470 in the range between 0.05 and 0.2 inches, whereineach hole 2420 has height 2474 in the range between 0.1 and 5.0 inchesand width in the range between 0.05 and 0.5 inches.

FIG. 25 illustrates one exemplary bearing cage 2500 that has beenpierced by stamping station 100 according to method 2100. Bearing cage2500 includes a radial wall 2510 and a lip 2520. Radial wall 2510 has aplurality of holes 2530 formed by stamping station 100. Bearing cage2500 is similar to pierced ring 1600. Each of holes 2530 may accommodatea tapered roller. Bearing cage 2500 may be of a material similar to thatof speed ring 2400 and have similar dimensions.

Combinations of Features

Features described above as well as those claimed below may be combinedin various ways without departing from the scope hereof. For example, itwill be appreciated that aspects of one system or method forslew-actuated piercing of a radial wall, or associated part with aradial wall, described herein may incorporate or swap features ofanother system or method for slew-actuated piercing of a radial wall, orassociated part with a radial wall, described herein. The followingexamples illustrate possible, non-limiting combinations of embodimentsdescribed above. It should be clear that many other changes andmodifications may be made to the systems and methods described hereinwithout departing from the spirit and scope of this invention:

(A1) A slew-actuated stamping station may include an expandable coreconfigured to apply radially outward pressure to a radially inwardfacing surface of a radial wall, and at least one slew-actuated punchfor piercing, along a radially inward direction, a respective hole inthe radial wall.

(A2) The stamping station denoted as (A1) may further include (a) adrive ring, (b) at least one punch holder, each connecting one or moreof the at least one slew-actuated punch to the drive ring, (c) a guidefor guiding each punch holder toward the radial wall, and (d) a firstslew for rotating the drive ring to drive each punch holder along theguide so as to pierce the radial wall with each slew-actuated punch.

(A3) In the stamping station denoted as (A2), one or more of the atleast one punch holder may have exactly one punch mounted thereon.

(A4) In either of the stamping stations denoted as (A2) and (A3), one ormore of the at least one punch holder may have more than one punchmounted thereon.

(A5) In any of the stamping stations denoted as (A2) through (A4), eachpunch holder may include (i) a punch body having the respective one ormore of the at least one slew-actuated punch attached thereto, whereinthe guide is configured to guide the punch body, and (ii) a leverconnecting the punch body to the drive ring, wherein the lever iscoupled both to the punch body, via a proximate joint that allowspivoting of the lever relative to the punch body, and to the drive ring,via a distal joint that allows pivoting of the lever relative to thedrive ring, such that said rotation of the drive ring moves the punchbody along the guide.

(A6) In the stamping station denoted as (A5), each punch holder may beconfigured to place the respective punch body at its radially mostinward position when the lever is parallel to the punch body.

(A7) Any of the stamping stations denoted as (A2) through (A6) mayfurther include a second slew for cooperating with the first slew torotate the drive ring.

(A8) In the stamping station denoted as (A7), the first slew and thesecond slew may be coupled to opposite sides of the drive ring.

(A9) Any of the stamping stations denoted as (A1) through (A8) mayfurther comprising a tapered plunger capable of moving along axialdimension of the radial wall, and the expandable core may include aplurality of tapered die segments arranged about the tapered plungersuch that the tapered die segments move radially outward when thetapered plunger is moved to interface with the tapered die segments at agreater diameter of the tapered plunger.

(A10) In the stamping station denoted as (A9), the plurality of tapereddie segments may include a respective plurality of radially outwardfacing surfaces for applying the outward pressure to the radially inwardfacing surface of the radial wall when the tapered plunger forces thetapered die segments radially outward.

(A11) In the stamping station denoted as (A10), the radially outwardfacing surfaces of the tapered die segments may approximate a finalshape of the radially inward facing surface of the radial wall toachieve the final shape of the radial wall when the tapered die segmentsapply the radially outward pressure.

(A12) In the stamping station denoted as (A11), the final shape may becylindrical or conical.

(A13) In either of the stamping stations denoted as (A11) and (A12), thefinal shape may be characterized by a circular cross section at everyaxial position within axial extent of the radial wall.

(A14) In any of the stamping stations denoted as (A9) through (A13), thetapered die segments may form one or more chutes configured to receiveand drop material removed from the radial wall by said piercing.

(A15) In any of the stamping stations denoted as (A1) through (A14), theat least one slew-actuated punch may include a plurality ofrectangularly shaped punches for piercing a respective plurality ofrectangular holes in the radial wall.

(A16) In any of the stamping stations denoted as (A1) through (A15), theat least one slew-actuated punch may include a plurality ofrectangularly shaped punches for piercing a respective plurality ofholes at equidistant azimuthal positions of the radial wall.

(A17) Any of the stamping stations denoted as (A1) through (A16) may beimplemented in a stamping system that further includes a secondslew-actuated stamping station, wherein the second slew-actuatedstamping station includes (I) a second expandable core for holding theradial wall after piercing of the radial wall in the slew-actuatedstamping station, the second expandable core being configured applyradially outward pressure to the radially inward facing surface, and(II) at least one second slew-actuated punch for piercing, along aradially inward direction, at least one respective second hole in theradial wall or change shape of one or more of the at least one firsthole.

(B1) A method for piercing a radial wall may include simultaneously (a)applying radially outward pressure against a radially inward facingsurface of the radial wall, and (b) driving a slew to actuate at leastone punch to pierce, along direction opposite the radially outwardpressure, at least one hole in the radial wall.

(B2) In the method denoted as (B1), the step of applying may includeexpanding a core to apply the radially outward pressure.

(B3) In the method denoted as (B2), the step of expanding may includeusing a tapered plunger to push a plurality of tapered die segments,positioned inside the radial wall, radially outward.

(B4) In any of the methods denoted as (B1) through (B3), the step ofapplying may include achieving a final shape of the radially inwardfacing surface.

(B5) In the method denoted as (B4), the step of applying may furtherinclude preventing at least one of (a) burrs in the radial wall and (b)distortions of the radial wall.

(B6) In either of the methods denoted as (B4) and (B5), the step ofachieving may include achieving that the radially inward facing surfacehas circular cross section at every axial position of the radial wall.

(B7) In any of the methods denoted as (B4) through (B6), the step ofachieving may include achieving that the radially inward facing surfaceis cylindrical or conical.

(B8) In any of the methods denoted as (B1) through (B7), the step ofdriving may include (i) driving the slew to rotate a drive ring, coupledto the slew and each punch, so as to move each punch, and (ii) guidingmovement of each punch along a radially-inward direction to pierce theradial wall.

(B9) In the method denoted as (B8), the step of driving may includemoving a plurality of punches coupled to the drive ring, and guidingeach of the punches along a respective radially-inward direction topierce a plurality of holes in the radial wall.

(B10) The method denoted as (B9) may include (I) in the step of driving,azimuthally shifting position of distal end of each of at least onelever coupled to the drive ring, and (II) in the step of guiding,guiding radially-inward movement of each of at least one punch body that(1) is connected to proximate end of a respective one of the at leastone lever and (2) has one or more respective ones of the at least onepunch mounted thereon, to pierce the at least one hole.

(B11) Any of the methods denoted as (B1) through (B10) may includeperforming the steps of applying and driving in a first stamping stationto pierce at least one hole in the radial wall, and performing the stepsof applying and driving in a second stamping station to pierce at leastone second hole in the radial wall or change shape of one or more of theat least one first hole.

(C1) A method for forming an object having a radial wall with holes mayinclude forming a ring with a radial wall, and piercing at least onehole in the radial wall with at least one slew-actuated punch.

(C2) The method denoted as (C1) may further include, after the step ofpiercing, modifying shape of the ring.

(C3) In the method denoted as (C2), the step of modifying may includeroll-forming the ring.

(C4) In any of the methods denoted as (C1) through (C3), the step ofpiercing may include applying radially outward pressure against aradially inward facing surface of the radial wall, and driving a slew toactuate at least one punch to pierce, along direction opposite theradially outward pressure, at least one hole in the radial wall.

(C5) In the method denoted as (C4), the step of applying may includeachieving a final shape of the radial wall.

(C6) In either of the methods denoted as (C4) and (C5), the step ofapplying may further include preventing at least one of (a) burrs in theradial wall and (b) distortions of the radial wall.

(C7) In any of the methods denoted as (C1) through (C6), the step offorming may include roll-forming a flat sheet into a ring.

(C8) In the method denoted as (C7), the step of roll-forming may furtherinclude roll-forming, in the ring, a plurality of sections along axialdimension of the ring, at least two of the sections having mutuallydifferent polar angles relative to axis of the ring.

(C9) In any of the methods denoted as (C1) through (C6), the step offorming may include cutting the ring from a tube.

(C10) In any of the methods denoted as (C1) through (C9), the step offorming may include forming the ring such that the radial wall iscylindrical or conical.

(C11) In any of the methods denoted as (C1) through (C10), the step offorming may include forming the ring such that cross section of theradial wall, at every axial position, is circular.

Changes may be made in the above systems and methods without departingfrom the scope hereof. It should thus be noted that the matter containedin the above description and shown in the accompanying drawings shouldbe interpreted as illustrative and not in a limiting sense. Thefollowing claims are intended to cover generic and specific featuresdescribed herein, as well as all statements of the scope of the presentsystems and methods, which, as a matter of language, might be said tofall therebetween.

What is claimed is:
 1. A method for piercing a radial wall, comprisingsimultaneously: applying radially outward pressure against a radiallyinward facing surface of the radial wall; and driving a slew to actuateat least one punch to pierce, along a direction opposite the radiallyoutward pressure, at least one hole in the radial wall.
 2. The method ofclaim 1, wherein said applying comprises expanding a core to apply theradially outward pressure.
 3. The method of claim 2, wherein saidexpanding comprises using a tapered plunger to push a plurality oftapered die segments, positioned inside the radial wall, radiallyoutward.
 4. The method of claim 1, wherein said applying comprisesachieving a final shape of the radially inward facing surface.
 5. Themethod of claim 4, wherein said applying further comprises preventing atleast one of (a) burrs in the radial wall and (b) distortions of theradial wall.
 6. The method of claim 4, wherein said achieving comprisesachieving that the radially inward facing surface has circular crosssection at every axial position of the radial wall.
 7. The method ofclaim 4, wherein said achieving comprises achieving that the radiallyinward facing surface is cylindrical or conical.
 8. The method of claim1, wherein said driving the slew to actuate at least one punch includes:driving the slew to rotate a drive ring, coupled to the slew and the atleast one punch, to move the at least one punch; and guiding movement ofthe at least one punch along a radially-inward direction to pierce theradial wall.
 9. The method of claim 8, wherein said driving the slew torotate the drive ring comprises: moving a plurality of punches coupledto the drive ring; and guiding each of the plurality of punches along arespective radially-inward direction to pierce a plurality of holes inthe radial wall.
 10. The method of claim 8, wherein: said driving torotate a drive ring includes azimuthally shifting a position of a distalend of each of at least one lever coupled to the drive ring; and saidguiding includes guiding radially-inward movement of each of at leastone punch body that (a) is connected to proximate end of a respectiveone of the at least one lever and (b) has one or more respective ones ofthe at least one punch mounted thereon, to pierce the at least one hole.11. The method of claim 1, wherein: said applying and driving areperformed in a first stamping station to pierce at least one hole in theradial wall; and said applying and driving are performed in a secondstamping station to pierce at least one second hole in the radial wallor change shape of one or more of the at least one first hole.
 12. Amethod for forming an object having a radial wall with holes,comprising: forming a ring with a radial wall; and piercing at least onehole in the radial wall with at least one slew-actuated punch.
 13. Themethod of claim 12, further comprising modifying, after said piercing, ashape of the ring.
 14. The method of claim 13, wherein said modifyingcomprises roll-forming the ring.
 15. The method of claim 12, whereinsaid piercing comprises: applying radially outward pressure against aradially inward facing surface of the radial wall; and driving a slew toactuate at least one punch to pierce, along direction opposite theradially outward pressure, at least one hole in the radial wall.
 16. Themethod of claim 15, wherein said applying comprises achieving a finalshape of the radial wall.
 17. The method of claim 16, wherein saidapplying further comprises preventing at least one of (a) burrs in theradial wall and (b) distortions of the radial wall.
 18. The method ofclaim 12, wherein said forming comprises roll-forming a flat sheet intoa ring.
 19. The method of claim 18, wherein said roll-forming furthercomprises roll-forming, in the ring, a plurality of sections along axialdimension of the ring, at least two of the sections having mutuallydifferent polar angles relative to axis of the ring.
 20. The method ofclaim 19, wherein said forming comprises cutting the ring from a tube.21. The method of claim 12, wherein said forming comprises forming thering such that the radial wall is cylindrical or conical.
 22. The methodof claim 12, wherein said forming comprises forming the ring such thatcross section of the radial wall, at every axial position, is circular.